Truck sleeper cab

ABSTRACT

A sleeper cab unit for mounting on a truck comprising a one-piece outer shell made of reinforced fibreglass plastic material having core materials laminated to inside surfaces of the shell and with window and door and other openings cut through the shell and insulating materials and wall covering materials affixed to the inside surfaces of the shell.

BACKGROUND & SUMMARY OF INVENTION

This invention relates to cab units, such as sleeper cab unit cabs foruse with trucks and the like.

In the past, truck-tractor-trailer rigs used for long distance haulingof goods have sometimes been provided with sleeping compartments for thedrivers. The sleeping compartments have been provided in the rear of andas part of the truck cab itself. In other instances, the sleepingcompartment has been provided in a separate sleeping cab unit mounted onthe truck frame behind the truck cab.

In general, the present invention relates to the construction andmethods of construction of sleeping cab units mounted on the truck framebehind the truck cab. The sleeping cab unit comprises a one-piece outerbox-like shell made of fiberglass reinforced plastic materials with corematerials integrally bonded to interior surfaces of the shell withoutjoints or seams or separate connecting devices such as rivets and boltsso as to prevent water and air leakage. The sleeping cab unit is ofrelatively light weight and relatively high strength as compared withprior art units. In addition, wind resistance and the cost ofmanufacture have been significantly reduced while also providingimproved insulation and eliminating vibrational problems. Maintenanceproblems have been reduced, appearance has been substantially improvedand comfort has been greatly increased resulting in less fatigue to thedriver and improved safety.

In the presently preferred and illustrative embodiment of the invention,the sleeping cab unit comprises a one-piece box-type shell having abottom wall portion providing a floor, an upper wall portion providing aroof, front and rear vertically extending side wall portions and a pairof vertically extending side wall portions made of fiberglass reinforcedplastic material with lightweight porous core materials integrallybonded to the fiberglass to form a high-strength lightweight solidone-piece integral sleeping cab unit. After forming of the closed shellwith the core materials attached thereto, various openings, such as forwindows and doors, are cut through the wall portions. The inside of thesleeping cab unit is then finished by mounting of covering materials onthe core materials. The inside of the sleeping cab unit may have variousbuilt-in accessory structures such as a sleeping bunk or shelf forsupporting a mattress, cabinets for storing articles and clothes,receptacles for appliances, such as refrigerators and cooling devices.Other features of the present invention include mounting frame structurefor attachment of the sleeping cab to the truck frame, and tunnel meansfor connection of the truck cab directly to the sleeper cab.

BRIEF DESCRIPTION OF DRAWINGS

Illustrative and presently preferred embodiments of the invention areshown in the accompanying drawing wherein:

FIG. 1 is a front side perspective view of a sleeping cab unit of thepresent invention;

FIG. 2 is another rear side perspective view of the sleeping cab unit;

FIG. 3 is a side elevational view of the sleeping cab unit as mounted ona truck;

FIG. 4 is a cross-sectional perspective view of a portion of a cab shellshowing the floor and side wall construction;

FIG. 5 is a cross-sectional view of a finished side wall portion of thesleeping cab unit;

FIG. 6 is a cross-sectional view of a finished bottom wall portion ofthe sleeping cab unit;

FIG. 7 is a partial perspective view of a finished portion of theinterior of the sleeping cab unit;

FIG. 8 is a bottom perspective view of a portion of the sleeping cabunit showing a mounting frame for mounting the sleeping cab unit on thetruck frame;

FIG. 9 is a cross-sectional view of tunnel means extending between atruck cab and the sleeping cab unit; and

FIG. 10 is an enlarged cross-sectional view of connecting and sealingmeans associated with the tunnel means.

DETAILED DESCRIPTION

In general, as shown in FIGS. 1-3, the sleeping cab unit 10 of thepresent invention is mounted on the truck frame 12 behind and adjacentthe rear wall 14 of the truck operation cab 16. Sleeping cab unit 10comprises a front side wall portion 20, a rear side wall portion 21,side wall portions 22, 23, a bottom floor wall portion 24, and an upperroof wall portion 25. The side wall portions 20, 21, 22, 23 may beupwardly tapered to increase rigidity.

An entry door 30 may be provided in one side wall portion and windowunits 32 may be provided in any of the side wall portions. The upperroof portion 25 may be flat or have a dome-shape construction comprisingV-shape inclined uppermost front wall portions 34, 35 with window units36, 37; inclined uppermost side wall portions 38, 39; lowermost inclinedside wall portions 40, 41, 42, 43; and a flat or curved upper wallportion 44.

The sleeping cab unit is manufactured by first forming a closed box-likeshell as a complete solid wall enclosure without any seams or openings.Door and window openings are subsequently cut through the walls anddoors and windows are mounted therein in sealed relationship thereto.The shell has a continuous integrally connected one-piece outer wallformed by a layer of fiberglass reinforced plastic material (FRP) suchas polyester resin with chop strand mat or unidirectional mat, having awall thickness of approximately between 0.125 to 0.1875 inch. The bottomwall portion may be separately formed with upwardly, inwardly taperedside surfaces and placed within and integrally bonded to correspondingupwardly inwardly tapered side surfaces of the side wall portions. Asshown in FIGS. 4 and 6, the roof and floor portions have a core materialsuch as a sheet 50 of balsa wood material laminated to the insidesurfaces 52 of the roof and floor portions of the one-piece outer wallof FRP material. The interior surfaces 54 of the side wall portions ofthe FRP material have laterally spaced bracing strip members such asbalsa wood firring strips 56, 58 laminated thereto. Balsa wood ispresently preferred for the laminating material because it islightweight and has sufficient porosity to enable the FRP material topenetrate and be integrally connected and rigidly bonded thereto asindicated by layer 60, FIG. 4. In a preferred embodiment, the balsa woodfloor sheet material 50 has a thickness of 3/4 inch, the roof sheet corematerial (not shown) has a thickness of 1/4 inch, and the side wallfirring strips 56, 58 have a thickness of approximately 3/4 inch and awidth of approximately 2 inches and are spaced on 1 foot center lines.It is contemplated that other kinds of core materials may be employed.For example, the side wall bracing strip members 56, 58 may be made ofreinforced fiber glass plastic material and the floor sheet member 50may be made of plywood or particle board or the like.

After the basic unit has been manufactured, the door and window openingsare cut into the wall portions in accordance with any particular set ofdesign specifications. Then the interior of the unit is finished inaccordance with any particular design specifications. Air conditioningducts, electrical wiring conduit, electrical outlets, electricalfixtures and the like (not shown) are fixedly mounted on the insidesurfaces of the wall portions by bonding with fiberglass materials orother suitable adhesive type materials and/or by screws into the corematerials. Internal structures, such as cabinets and shelves, aresimilarly fixedly mounted on the wall portions and core materials. Forexample, as shown in FIG. 7, a sleeping platform 61 for supporting amattress may be mounted along the rear wall portion which may include anescape hatch 62. A support cabinet 63 for a refrigerator 64 and/or stoveunit 66 may be mounted along a side wall portion. The inside surfaces ofthe portions are covered by suitable insulation and wall coveringmaterial.

In the presently preferred embodiment, FIGS. 4 and 5, a plastic foammaterial, such as styrene foam sheet material 70, is adhesively bondedto the inside wall surfaces. In an alternative embodiment, plastic foammaterial may be sprayed onto the surfaces. A wall covering material 71,FIG. 5, such as a plastic sheet material or panel members or paddedupholstery material, is mounted over the core material and theinsulation material by adhesive bonding and/or screw devices applied tothe core material. The interior structures, such as cabinets and shelvesand the like, are preferably covered with padded upholstery material 72as shown in FIG. 7.

As shown in FIG. 6, the floor portion may be insulated and carpeted witha foam pad 73 and carpet 74. Electrical conduit and electrical wiringand electrical connections (not shown), and electrical fixtures such aslamps 76, FIG. 7, may be mounted between the paneling material and theside wall portions.

As shown in FIG. 8, the bottom wall portion 24 is preferably providedwith reinforcement rib means 80, 82, 84 and side wall portions 20, 21,22, 23 extend downwardly beyond the lower surface of bottom wall portion24 to provide a rim portion 86 defining a frame cavity 88. A rigidmetallic frame means 90 is mounted in frame cavity 88 and fixed to thebottom wall portion 24 and floor core sheet portion 50 by suitablesealed bolt means 92. Frame means 90 comprises a central portion 94having a width approximately equal to the width of the truck frame andwing portions 95, 96. Reinforcement plate means 97 and 98 are providedon the central frame portion.

As shown in FIGS. 9 & 10, in a preferred embodiment of the invention, anaccess opening 100 is provided in the front sleeping cab wall portion 20for location opposite a corresponding opening 102 in the rear wallportion 104 of the truck cab. These openings are connected by a tunnelmeans 108 made of a conventional resilient flexible pleated material,such as EDPM rubber material which is not subject to degradation byultra violet light, solvents, or temperature variations, to enable aperson to move directly between the truck cab to the sleeping cab. Thetunnel means 108 has accordion-like pleats 110 to accommodate relativemovement between the truck cab and the sleeping cab. Sealing andfastening means 112 are provided on end portions 114 and 116 in the formof a groove 118 which receives a clamping member 120 made of springsteel material with lip portions 122, 124 defining a groove 126 forreception of the wall edge portion 128. The construction and arrangementis such as to provide an elongated tunnel member having a wall portionmade of flexible plastic material and an elongated crawl passageextending therethrough between opposite end openings. A flexible annularrib portion is on and extends about each end of the tunnel member andsurrounding each of the end openings and an annular mounting groove isin and extends around each rib portion. A resilient annular clip meansis mounted in each angular mounting groove and is resiliently retainedtherein and has a pair of opposed annular spring finger portions forgripping the side wall surfaces about the tunnel wall openings. Thetunnel member has pleats extending therealong. Each annular mountinggroove has a C-shape cross-section and the clip means has acorresponding larger size C-shape cross-section so as to compress therib portion against the clip means. The spring finger portions of theclip means have reversely bent terminal portions and the rib means hascorresponding reversely bent lip portions which cover said terminalportions. The spring finger portions of the clip means have reverselybent terminal portions and the rib means have corresponding reverselybent lip portions which cover the terminal portions.

Thus, the present invention comprises a self-contained cab sleeper unitattachment for trucks of all types. The basic construction consists of aone-piece box-type outer shell constructed of laminated F.R.P. materialand core materials of either balsa wood or other materials which equalor exceed balsa wood characteristics. Sheet core materials are placed onthe ceiling and floor. Side walls have wood firring strips laminated tothe walls for increased rigidity and to facilitate the installation ofthe interior insulation, finish and appointments. While the constructionis particularly well suited for manufacture of a sleeper cab unit for atruck or the like, the construction may be employed for manufacture ofsimilar type units for other purposes.

The outer shell of the sleeper unit is of one-piece construction with noseams or separately attached wall pieces. The physical size and shape ofthe unit can be adjusted to meet any requirements or specifications. Incase of damage, the F.R.P. laminate has inherent memory capabilities andis inclined to retain its shape. It will not migrate as will metal.F.R.P. laminate does not fatigue or stress as will metal construction.All sides and curves of the unit are smooth-flowing with no air traps todisturb the airflow. Solid color finishes can be impregnated into theoutside finish of the shell or be painted. The sleeper cab comprises afront wall portion, a rear wall portion and a pair of side wallportions, and a bottom wall portion. The front wall portion has aperipheral configuration substantially the same as the peripheralconfiguration of the truck cab rear wall.

Advantages of the one-piece design are that water and air leakageproblems inherent with all other present designs are eliminated. The useof similar or dissimilar material attachments to complete theconstruction is eliminated. The problems that occur with the use of poprivets and the expansion and contraction of dissimilar materials are nolonger a factor and the possibilities of leaks cannot occur. The bondingof the core material into the structure creates the following advantagesover present construction methods: (1) greatly increased strength; (2)reduction in weight; (3) sound attenuation; and (4) insulation qualitiesthat are bonded into place. The inside floor plan, doors, windows andinside appointments can be customized to the customers' specifications.The completed assembly can be attached to the truck cab with no water orair leaks and still maintain easy access to and from the cab. Completedassemblies are approximately 30 to 50% lighter than conventionaldesigns. Maintenance time is reduced and excellent appearance isachieved with minimal effort.

The inventive concepts have been disclosed in connection withillustrative and preferred embodiments may be variously otherwiseemployed in alternative embodiments, and it is intended that theappended claims be constructed to include modifications, except insofaras limited by the prior art.

What is claimed is:
 1. A sleeper cab unit for mounting on atractor-truck having a tractor-truck operating cab and a rear-mountedhitch for hauling a trailer and the sleeper cab unit being locatedadjacent and behind a tractor-truck operating cab by attachment to thetractor-truck frame and comprising:an outer shell made of one piece ofcontinuously integrally connected molded fiberglass reinforced plasticmaterial having vertical side wall portions, an upper roof portion and alower floor portion providing a continuous wall and defining a box-likestructure having interior side surfaces and exterior side surfaces; aplurality of laterally spaced separate reinforcement strip membersintegrally bonded to the interior surfaces of said vertical side wallportions; a separate flat rigid board-like reinforcement sheet memberintegrally bonded to the interior surface of said floor portion; aseparate flat rigid board-like reinforcement sheet member integrallybonded to the interior surface of said roof portion; cut-out windowopening means cut through said continuous wall in at least one of saidside wall portions for enabling installation of a window unit; a windowunit mounted in each of said cut-out window opening means in sealedsupporting relationship with said continuous wall; cut-out door openingmeans cut through said continuous wall in at least one of said side wallportions for enabling installation of a door unit; a door unit mountedin each of said cut-out door opening means in sealed supportingrelationship with said continuous wall; mounting means associated withsaid floor portion for fixedly mounting the sleeper cab unit on thetruck frame behind and adjacent the truck cab; said reinforcement stripmembers are made of fiberglass material; and each reinforcement sheetmember being made of one piece of wood material.
 2. The invention asdefined in claim 1 and further comprising:insulation material meansmounted on the interior surfaces of said side wall portions and saidroof portion by integral bonding therewith for providing a layer ofinsulation material thereover.
 3. The invention as defined in claim 1and wherein said box-like structure comprises:a front wall portion, arear wall portion, a pair of side walls portions; said front wallportion having a peripheral configuration substantially the same as theperipheral configuration of the truck cab rear wall; said roof portionand said rear wall portion extending above the roof of the truck cab;and said roof portion including a dome-shape uppermost wall portion, apair of intersecting rearwardly inclined forwardly facing wall portions,and a pair of upwardly inclined wall portions.
 4. A sleeper cab unit formounting on a tractor-truck having a tractor-truck operating cab and arear-mounted hitch for hauling a trailer and the sleeper cab unit beinglocated adjacent and behind a tractor-truck operating cab by attachmentto the tractor-truck frame and comprising:an outer shell made of onepiece of continuously integrally connected molded fiberglass reinforcedplastic material having vertical side wall portions, an upper roofportion and a lower floor portion providing a continuous wall anddefining a box-like structure having interior side surfaces and exteriorside surfaces; a plurality of laterally spaced separate reinforcementstrip members integrally bonded to the interior surfaces of saidvertical side wall portions; a separate flat rigid board-likereinforcement sheet member integrally bonded to the interior surface ofsaid floor portion; a separate flat rigid board-like reinforcement sheetmember integrally bonded to the interior surface of said roof portion;cut-out window opening means cut through said continuous wall in atleast one of said side wall portions for enabling installation of awindow unit; a window unit mounted in each of said cut-out windowopening means in sealed supporting relationship with said continuouswall; cut-out door opening means cut through said continuous wall in atleast one of said side wall portions for enabling installation of a doorunit; a door unit mounted in each of said cut-out door opening means insealed supporting relationship with said continuous wall; mounting meansassociated with said floor portion for fixedly mounting the sleeper cabunit on the truck frame behind and adjacent the truck cab; saidreinforcement strip members are made of fiberglass material; and eachsaid reinforcement sheet member being made of one piece of woodmaterial; said reinforcement strip members and each reinforcement sheetmember being made of a porous lightweight material; insulation materialmeans mounted on the interior surfaces of said side wall portions andsaid roof portion by integral bonding therewith for providing a layer ofinsulation material thereover; and a cover material mounted over saidinsulation material means for providing a finished interior surface. 5.The invention as defined in claim 4 and wherein:said porous lightweightmaterial is one piece of wood sheet material.
 6. The invention asdefined in claim 5 and wherein:said porous lightweight material is balsawood.
 7. The invention as defined in claim 4 and further comprising:abunk means mounted inside said box-like structure and being fixedlyattached to a portion of said continuous wall by integral bondingtherewith for providing a sleeping area.
 8. The invention as defined inclaim 7 and further comprising:cabinet means mounted inside saidbox-like structure and being fixedly attached to a portion of saidcontinuous wall by integral bonding therewith for providing a storagespace.
 9. The invention as defined in claims 2 or 4 and wherein:saidinsulation material means comprises a foam plastic material.
 10. Theinvention as defined in claim 9 and wherein:said insulation materialmeans comprises a spray coated foam plastic material.
 11. The inventionas defined in claims 2 or 4 and further comprising:a cover materialmounted over said insulation material means for providing a finishedinterior surface.
 12. The invention as defined in claim 11 and furthercomprising:a layer of insulation material mounted on said sheetreinforcement member on said floor portion; and a layer of carpetmaterial mounted on said layer of insulation material.
 13. The inventionas defined in claim 12 and further comprising:a layer of insulationmaterial integrally bonded to the interior surface of said roof portion;and a covering material integrally bonded to said layer of insulationmaterial.
 14. The invention as defined in claim 13 and wherein said roofportion comprising:a pair of forwardly facing rearwardly outwardly andupwardly inclined intersecting front wall portions providing a V-shapefront roof section.
 15. The invention as defined in claim 14 and furthercomprising:a cut-out window opening in each of said inclined wallportions; and a window unit mounted in each cut-out window opening insealed supporting relationship with said continuous wall.
 16. Theinvention as defined in claim 15 and wherein said roof portion furthercomprising:a pair of upwardly inclined laterally oppositely spaced wallportions extending rearwardly from said intersecting front wallportions.
 17. The invention as defined in claim 16 and wherein said roofportion further comprising:a convexly outwardly curved uppermost wallportion connecting said intersecting front wall portions and saidoppositely spaced wall portions.
 18. The invention as defined in claims1 or 4 and further comprising:a cut-out forwardly facing tunnel openingcut through said continuous wall in a front side wall portion adjacent atruck cab rear wall portion of the truck cab and being located oppositea rearwardly facing tunnel opening in the truck cab rear wall; and atunnel means connected to and extending between the truck cab rear walland the front side wall portion of the sleeping cab unit for enablingmovement of a person therebetween through said tunnel means.
 19. Theinvention as defined in claim 18 and wherein said tunnel meanscomprising:an elongated tubular member made of flexible material havingan elongated passage therewithin and oppositely spaced openings at eachend thereof; and attachment means associated with said openings forattachment to said truck cab rear side wall and to said sleeping cabfront side wall about the tunnel openings therein.
 20. The invention asdefined in claim 19 and wherein:said tubular member being made ofpleated rubber material.
 21. The invention as defined in claim 20 andwherein said attachment means comprising:a rib portion at each end ofsaid tubular member having an annular groove therein; and a resilientmetallic clip member mounted in said groove and having a pair ofresilient spring finger portions adapted to grippingly engage the truckcab rear side wall and the sleeping cab front side wall around thetunnel openings therein.
 22. The invention as defined in claims 1 or 4and wherein said mounting means comprising:reinforcement rib means insaid floor wall portion; and a rigid metallic frame member fixedlymounted on said floor wall portion.
 23. The invention as defined inclaim 22 and further comprising:a frame cavity in the bottom portion ofsaid sleeping cab unit defined by said floor portion and said side wallportions; and said frame member having a size and shape corresponding toand being mounted within said frame cavity and having a central portionfor attachment to the truck frame and wing portions for supportingportions of the sleeping cab unit extending laterally beyond the truckframe.
 24. Apparatus for providing a crawl tunnel between thelongitudinally spaced side walls of a truck cab and a sleeper cabmounted adjacent thereto having tunnel wall openings thereincomprising:an elongated tunnel member having a wall portion made offlexible plastic material and an elongated crawl passage extendingtherethrough between opposite end openings; a flexible annular ribportion on and extending about each end of said tunnel member andsurrounding each of said end openings and an annular mounting groove inand extending around each rib portion; a resilient annular clip meansmounted in each annular mounting groove and being resiliently retainedtherein and having a pair of opposed annular spring finger portions forgripping the side wall surfaces about the tunnel wall openings; saidtunnel member having pleats extending therealong; each annular mountinggroove having a C-shape cross-section and said clip means having acorresponding larger size C-shape cross-section so as to compress saidrib portion against said clip means; and said spring finger portions ofsaid clip means have reversely bent terminal portions and said rib meanshas corresponding reversely bent lip portions which cover said terminalportions.
 25. A method of construction of a sleeping cab unit formounting on the frame of a truck behind the truck cabcomprising:constructing an outer shell made of one piece of moldedfiberglass reinforced plastic material having vertical side wallportions, an upper roof portion and a lower floor portion providing acontinuous wall and defining a box-like structure having interior sidesurfaces and exterior side surfaces; integrally bonding a plurality oflaterally spaced reinforcement strip members to the interior surfaces ofsaid vertical side wall portions; integrally bonding a sheetreinforcement member to the interior surface of said floor portion;integrally bonding a sheet reinforcement member to the interior surfaceof said roof portion; forming window opening means by cutting throughsaid continuous wall in at least one of said side wall portions forenabling installation of a window unit; mounting a window unit in eachof said window opening means in sealed supporting relationship with saidcontinuous wall; forming door opening means by cutting through saidcontinuous wall in at least one of said side wall portions for enablinginstallation of a door unit; and mounting a door unit in each of saidcut-out door opening means in sealed supporting relationship with saidcontinuous wall.
 26. The invention as defined in claim 25 and furthercomprising:mounting insulation material means and cover material meanson the interior surfaces of said side wall portions and said roofportion by integral bonding therewith for providing a layer ofinsulation material and a finished interior surface thereover.
 27. Theinvention as defined in claim 26 and further comprising:mounting a bunkmeans inside said box-like structure by integral bonding to a portion ofsaid continuous wall for providing a sleeping area.
 28. The invention asdefined in claim 27 and further comprising:mounting cabinet means insidesaid box-like structure by integral bonding to a portion of saidcontinuous wall for providing a storage space.